AIion Energy Systems Inc. is a U.S.-based battery manufacturer built on more than 18 years of intensive lithium battery chemistry research, development, and energy storage manufacturing experience. Our work culminated in the creation of AIion Safe™ batteries—engineered for exceptional safety, high performance, rapid charge and discharge capability, and very long cycle life.
AIion operates from a 32,000 sq. ft. manufacturing facility in Englewood, Colorado, including a 1,600 sq. ft. state-of-the-art dry room to support advanced cell production. As a domestic battery manufacturer, we help customers reduce risk, accelerate development timelines, and scale with confidence.
U.S. Manufacturing That Supports Mission-Critical Performance
Domestic manufacturing is more than a location. It’s a capability. By designing and building in the U.S., AIion delivers the control, speed, and quality consistency mission-critical programs demand. We support partners who require high reliability, strong process discipline, and rapid iteration—without compromising safety or performance.
As a Colorado-based battery manufacturer, AIion is positioned to serve both government and commercial partners with the responsiveness and accountability that comes from domestic operations.
Facility Highlights
AIion’s Englewood facility is built to support advanced lithium battery development and production with a focus on safety, repeatability, and flexibility.
Key facility highlights include:
- 32,000 sq. ft. domestic manufacturing footprint in Englewood, CO
- 1,600 sq. ft. dry room supporting advanced cell production
- Agile manufacturing platform enabling rapid development and flexible configurations
- Designed to support both program requirements and commercial scale-up
What We Deliver
AIion provides a range of products and capabilities by leveraging unique strengths across chemistry, engineering, and manufacturing. As an experienced battery manufacturer, we help customers build solutions that meet demanding operational requirements while supporting fast development cycles.
Our core capabilities include:
- Advanced, high-performing electrochemistries
- Conformal battery and ultracapacitors development tailored to mission requirements
- An agile manufacturing platform enabling rapid development, flexible production commonality, and optimized SWaP-C
- Drop-in replacement cell solutions supporting existing DoW battery pack reconfiguration
Built for the Markets That Can’t Afford Failure
AIion designs and manufactures battery systems for environments where uptime, safety, and performance are non-negotiable. We support mission-critical applications across:
- Data centers and AI compute infrastructure
- Critical backup power
- U.S. Department of War programs
- OEM partners seeking high-performance energy storage
As demand grows across commercial hyperscale and AI infrastructure, AIion continues scaling readiness to meet requirements where footprint, total cost of ownership (TCO), and long-term reliability matter.
Manufacturing Timeline
AIion’s domestic manufacturing roadmap supports scale-up from early production through higher-volume output. This approach allows customers to qualify products to specification while preparing for future demand.
Limited Rate Initial Production (LRIP)
Initial scale-up from laboratory builds to early production using proprietary processes and controlled manufacturing steps. LRIP products support testing, validation, and customer qualification.
Pilot Scale Production
Expanded capability designed to support small to medium run quantities, customer purchases, and prospect qualifications. Pilot scale enables faster configuration changes and broader product flexibility.
High Speed Fully Automated Production
Future high-volume continuous production designed to meet major demand across mission-critical backup power and other energy sustainability needs.
AIion’s domestic manufacturing foundation is designed to support customers from early qualification through scalable production. As a U.S.-based battery manufacturer, we combine proven lithium battery expertise with an agile platform built for reliability, safety, and repeatable performance—helping partners meet demanding requirements today while preparing for the next stage of growth.